Polyisocyanate based polymers perpared from formulations including non-silicone surfactants and method for the preparation thereof

ABSTRACT

Polyurethane, polyisocyanurate and polyurea polymers, particularly foamed polymers can be prepared from formulations including non-silicone polyether surfactants. The non-silicone polyether surfactants can be polyethers having from about 10 to about 90 weight percent oxyethylene units and from about 10 to about 90 weight percent oxyalkylene units having at least 4 carbons. The non-silicone polyether surfactants can be used to prepare foams having properties substantially similar to foams prepared with conventional silicone based surfactants.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation in part of U.S. Ser. No. 08/169, 477,filed December 17, 1993, titled "POLYISOCYANATE BASED POLYMERS PREPAREDFROM FORMULATIONS INCLUDING NON-SILICONE SURFACTANTS AND METHOD FOR THEPREPARATION THEREOF", which is now abandoned.

BACKGROUND OF THE INVENTION

The present invention relates to polyisocyanate based polymers preparedfrom formulations including non-silicone surfactants. The presentinvention particularly relates to polyurethane, polyisocyanurate andpolyurea foams prepared from formulations including non-siliconesurfactants.

Polyisocyanate based polymers are known to be useful. Methylenediphenyldiisocyanate (MDI) and toluene diisocyanate (TDI) are usefulmonomeric polyisocyanates. Polymeric isocyanates, particularly polymericmethylene diphenyl diisocyanate (sometimes also referred to aspolymethylene polyphenyl polyisocyanate, hereinafter PMDI) are veryuseful polymeric intermediate materials. They are used primarily ascomponents in thermoset and thermoplastic polymer elastomers, and rigidand flexible polyurethane, polyurea and polyisocyanurate foams.Polyisocyanate based elastomers are used in applications such asreaction injection molded automobile body parts, injection moldedskateboard wheels, and extruded disposable diaper components.

Polymeric isocyanates are particularly valued for the excellentinsulating properties of foams prepared therewith. These insulatingfoams may be found in applications ranging from home construction to icechests and refrigerators and even to industrial applications such aspipe and vessel insulation. Such foams are typically rigid.

Flexible polyurethane foams are used in a wide variety of applications,such as bedding, furniture cushioning, automobile seating, headrests,dashboards, packaging, toys and the like. These foams are generallyprepared by reacting a nominally di- or trifunctional, high equivalentweight polyol with a polyisocyanate, in the presence of a blowing agentand sometimes also in the presence of a minor amount of a crosslinker.

These foams are commonly separated into two types, according to theirmethod of manufacture. Molded foams are prepared by reacting thepolyurethane-forming components in a closed mold to produce foams havinga predetermined shape. In contrast, slab-stock foams are prepared bypermitting the foam components to freely rise against their own weight.

It is known in the art of preparing polymer foams wherein one of thereactants is a polyisocyanate to use surfactants to compatibilize thereaction mixture and to stabilize forming foams. Often these surfactantsare silicone based. For example, U.S. Pat. No. 5,064,872 to Monstrey, etal., discloses preparing polyisocyanurate foams from formulationsincluding a polyalkylsiloxane polyether copolymer foam stabilizer. U.S.Pat. Nos. 4,097,406 and 4,172,186 to Scott, et al., discloses preparingpolyurethane foams from formulations including the reaction product ofreacting a silicon tetrahalide with water and an alcohol followed bytransesterification with a polyether polyol.

While using silicone surfactants as stabilizers in polymer formulationsis very common, it is not necessarily always the best solution in everyapplication. One disadvantage of silicone surfactants is their cost.Silicone surfactant materials are often one of the most expensivecomponents in a polymer formulation. Therefore, it would be desirable inthe art of preparing polymers from formulations includingpolyisocyanates to include a non-silicone surfactant in the formulationwhich is significantly lower in cost than silicone surfactants impartingabout the same properties to the foams produced therewith.

SUMMARY OF THE INVENTION

In one aspect, the present invention is an active hydrogen containingcomposition comprising (A) a polyfunctional active hydrogen containingcompound, (B) an optional blowing agent, (C) an optional catalyst and(D) a non-silicone surfactant wherein the surfactant is a polyetherhaving from about 10 to about 90 weight percent oxyethylene units andfrom about 10 to about 90 weight percent oxyalkylene units having atleast 4 carbons and is substantially free of oxypropylene units.

In another aspect, the present invention is a polymer prepared from aformulation including: (1) a polyisocyanate, (2) a polyfunctional activehydrogen containing compound, (3) an optional blowing agent, (4) anoptional catalyst and (5) a non-silicone surfactant wherein thesurfactant is a polyether having from about 10 to about 90 weightpercent oxyethylene units and from about 10 to about 90 weight percentoxyalkylene units having at least 4 carbons and is substantially free ofoxypropylene units.

Another aspect of the present invention is a method of preparing apolymer comprising admixing a polymer formulation including (1) apolyisocyanate, (2) a polyfunctional active hydrogen containingcompound, (3) an optional blowing agent, (4) an optional catalyst and(5) a non-silicone surfactant wherein the surfactant is a polyetherhaving from about 10 to about 90 weight percent oxyethylene units andfrom about 10 to about 90 weight percent oxyalkylene units having atleast 4 carbons and is substantially free of oxypropylene units.

In still another aspect, the present invention is, in a method ofpreparing a polymer foam from a formulation including (1) apolyisocyanate, (2) a polyfunctional active hydrogen containingcompound, (3) a blowing agent, (4) an optional catalyst and (5) asurfactant, the improvement comprising using a formulation including anon-silicone surfactant wherein the surfactant is a polyether havingfrom about 10 to about 90 weight percent oxyethylene units and fromabout 10 to about 90 weight percent oxyalkylene units having at least 4carbons and is substantially free of oxypropylene units.

The present invention is also a composition prepared by a processcomprising capping a polyether which has from about 10 to about 90weight percent oxyethylene units and from about 10 to about 90 weightpercent oxyalkylene units having at least 4 carbons and is substantiallyfree of oxypropylene units with an amine or hydroxy reactive material.

Yet another aspect of the present invention is a composition of 15matter having the general formula: ##STR1## wherein I is thenon-alkoxy-reactive portion of an initiator; A and A' are independentlyO, N, or NH; E is an oxyethylene group; B is an oxybutylene group; P isan oxypropylene group; x, y are values such that the ratio of x:y isfrom 1:4 to 4:1; z is a value such that the total weight of oxypropyleneunits is less than 10 percent of the combined weight of oxyethyleneunits and oxybutylene units; R is from 1 to 8 depending upon thefunctionality of the initiator; Q and Q' are independently 1 if A or A'is O or NH and Q and Q' are 2 if A or A' is N; the total molecularweight of the compound is from 750 to 11,000; C is the remainder of acapping compound; and E and B are substantially in blocks.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In one embodiment, the present invention is a polymer prepared from aformulation including: (1) a polyisocyanate, (2) a polyfunctional activehydrogen containing compound, (3) an optional blowing agent, (4) anoptional catalyst and (5) a non-silicone surfactant. Polymers which canbe prepared from formulations of the present invention include but arenot limited to polyurethanes, polyisocyanurates, polyurethane modifiedpolyisocyanurates, polyureas and the like. The polymers can beelastomers, rigid foams or flexible foams. All of these materials can beformed by the reaction of a polyisocyanate and an active hydrogencontaining material, optionally in the presence of a blowing agent.

Surfactants often can be critical components in polymer formulations.The non-silicon surfactants of the present invention can perform atleast two important functions. The surfactant can act to compatibilizethe polyisocyanate with the other formulation components. This isparticularly important in foam formulations where fine foam cell size isneeded, such as, for example, in appliance foam wherein the foam canperform an insulative function. The surfactant acts to allow thepolyisocyanate and the other formulation components to be thoroughlyadmixed, with the blowing agent particularly being distributedthroughout the reaction admixture such that very small bubbles make upthe froth which eventually forms the foam.

The surfactants can also function to stabilize a foam. This isparticularly important in rigid foam applications. As a froth is formedin the reaction mixture, it is subject to destabilization untilsufficient polymer molecular weight builds to support it. Inunstabilized formulations, the bubbles of the froth can break andrelease the gasses which act to impart insulative properties to foam.Likewise, the weight of a rising, forming froth can build too quicklyfor in unstabilized foam formulations causing the foam to collapse underits own weight. In stabilizing the foam, the non-silicone surfactants ofthe present invention can act to prevent the bubbles of the froth frombreaking. The surfactants can also impart some dimensional stability tothe froth until the forming polymer has built sufficient molecularweight to support itself.

The surfactants of the present invention are non-silicone based. Thesurfactants of the present invention are polyethers having from about 10to about 90 weight percent oxyethylene units and from about 10 to about90 weight percent oxyalkylene units having at least 4 carbons. Suchweight percent calculation is made disregarding the weight of theinitiator. Preferably the weight ratio of oxyethylene units to otheroxyalkylene units in the surfactant is from about 1:4 to about 4:1. Morepreferably the weight ratio of oxyethylene units to other oxyalkyleneunits in the surfactant is from about 1:3 to about 3:1. Even morepreferably the weight ratio of oxyethylene units to other oxyalkyleneunits in the surfactant is from about 1:2 to about 2:1. Most preferablythe weight ratio of oxyethylene units to other oxyalkylene units in thesurfactant is about 1.5:2.0 to 2.0:1.5.

The polyether surfactants of the present invention are substantiallyfree of oxypropylene units. The inclusion of oxypropylene units into thebackbone of the polyether surfactants of the present invention cansubstantially decrease the surfactant characteristics thereof.Preferably, the polyether surfactants of the present invention includeless than 10 weight percent oxypropylene units, more preferably lessthan 5 weight percent oxypropylene units, even more preferably less than1 weight percent oxypropylene units, and most preferably no oxypropyleneunits.

The non-silicone polyether surfactants of the present invention have amolecular weight of from about 750 to about 11,000. Preferably they havea molecular weight of from about 1,000 to about 8,000 and morepreferably they have a molecular weight of from about 2,000 to about7,000. The non-silicone surfactants have a nominal functionality of fromabout 1 to about 8, preferably from about 2 to about 4 , and mostpreferably from about 2 to about 3.

The non-silicone surfactants of the present invention are prepared withethylene oxide and at least one other alkylene oxide having at least 4carbons. Preferably the other alkylene oxide has from 4 to about 8carbons, more preferably it has from 4 to about 6 carbons. Mostpreferably, the other alkylene oxide used to prepare the non-siliconesurfactants of the present invention is butylene oxide.

There are several ways to prepare the non-silicone surfactants of thepresent invention. In one embodiment, the surfactants of the presentinvention are prepared by forming a polybutylene oxide polyether bycombining a propylene glycol initiator and butylene oxide in thepresence of a basic catalyst. A block polymer is then prepared bycombining the polybutylene oxide with ethylene oxide in the presence ofa basic catalyst to form an ethylene oxide/butylene oxide blockpolyether. In another embodiment, the surfactants of the presentinvention can be prepared by first forming a polyethylene oxidepolyether and then forming a block polymer by combining the polyethyleneoxide with butylene oxide in the presence of a basic catalyst. Blockpolymers are useful for forming polyethers having comparatively lowermolecular weights, but it can be desirable to introduce some level ofrandomness for forming polyethers having molecular weights of greaterthan about 2,000. For example, in another embodiment, a surfactant ofthe present invention can be prepared by first forming a polybutyleneoxide as described above, and then combining the polybutylene oxide witha mixed feed of ethylene oxide and butylene oxide in the presence of abasic catalyst.

The non-silicone surfactants of the present invention can have a nominalfunctionality of from about 1 to about 8. While the surfactants of thepresent invention can be prepared in any way known to be useful forpreparing polyethers, they are typically prepared by combining aninitiator with an alkylene oxide in the presence of a basic catalyst.Selection of the initiator is important in determining the nominalfunctionality of the resulting surfactant. For example, methanol can beused as an initiator to prepare a surfactant having a nominalfunctionality of 1. Sucrose can be used to prepare a surfactant having anominal functionality as high as 8. Mixtures of initiators can also beused.

Special properties can be imparted to the non-silicone surfactants ofthe present invention by careful selection of initiators. For example,ethylene diamine can be used as an initiator. Other initiators includingcatalytic groups can also be used to prepare surfactants havingcatalytic properties. Initiators useful with the present inventioninclude those generally used to prepare polyether polyols such asalkanolamines, alcohols, amines and the like. Such initiators includebut are not limited to: 2-aminoethanol, ethylene glycol, propyleneglycol, 1,3-dihydroxypropane, 1,4-dihydroxybutane, and1,6-dihydroxyhexane, glycerol, 1,2,4-trihydroxybutane,1,2,6-trihydroxyhexane, 1,1,1-trimethylolethane,1,1,1-trimethylolpropane, pentaerythritol, polycaprolactone, xylitol,arabitol, sorbitol, mannitol, ethylene diamine, glycerin, ammonia,1,2,3,4-tetrahydroxy butane, fructose, sucrose and the like.

The surfactants of the present invention can be at least monoor higherhydroxy or amine functional. As such they can be incorporated intoprepolymers or capped with amine or hydroxy reactive materials. Forexample, the surfactants of the present invention can be incorporatedinto a isocyanate terminated prepolymer by reacting the surfactant witha stoichiometric excess of a polyisocyanate. Similarly, they can becapped with, for example, low molecular weight halo-alkanes, organicacid halides, and the like. Preferably, the capping material will notinclude a polyisocyanate reactive group. Capping with compounds whichresult in a surfactant non-reactive to polyisocyanates permits thesurfactant to be admixed with polyisocyanates without reaction wheresuch mixing is desirable. Capping is achieved by admixing a non-siliconsurfactant with a capping compound under reaction conditions sufficientto react the capping compound with the amine or hydroxy group of thenon-silicone polyether surfactant.

Capped polyether surfactants of the present invention have the followinggeneral formula: ##STR2## wherein I is the non-alkoxy-reactive portionof an initiator; A and A' are independently O, N, or NH; E is anoxyethylene group; B is an oxybutylene group; p is an oxypropylenegroup; x, y are values such that the ratio of x:y is from 1:4 to 4:1; zis a value such that the total weight of oxypropylene units is less than10 percent of the combined weight of oxyethylene units and oxybutyleneunits; R is from 1 to 8 depending upon the functionality of theinitiator; Q and Q' are independently 1 if A or A' is O or NH and Q andQ' are 2 if A or A' is N; the total molecular weight of the compound isfrom 750 to 11,000; C is the remainder of a capping compound; and E andB are substantially in blocks. For example, where the polyether isprepared with a propylene glycol initiator, a 1:1 ratio of oxyethyleneand oxybutylene, and is capped with acetic anhydride: A and A' are O; xand y are at a ratio of 1:1; z is 0; Q and Q' are 1; R is 2; I has theformula: ##STR3## and C has the formula: ##STR4##

One embodiment of the present invention is a polymer resulting from thereaction of a polyisocyanate and a polyfunctional active hydrogencontaining material. The polyisocyanate component can be advantageouslyselected from organic polyisocyanates, modified polyisocyanates,isocyanate-based prepolymers, and mixtures thereof. These can includealiphatic and cycloaliphatic isocyanates, but aromatic and especiallymultifunctional aromatic isocyanates are preferred. Preferred are 2,4-and 2,6-toluenediisocyanate and the corresponding isomeric mixtures;4,4'-, 2,4'- and 2,2'-diphenylmethanediisocyanate and the correspondingisomeric mixtures; mixtures of 4,4'-, 2,4'- and2,2'-diphenylmethanediisocyanates and polyphenyl polymethylenepolyisocyanates PMDI; and mixtures of PMDI and toluene diisocyanates.Also useful for preparing the present invention are aliphatic andcycloaliphatic isocyanate compounds such as1,6-hexamethylenediisocyanate;1-isocyanato-3,5,5-trimethyl-1-3-isocyanatomethyl-cyclohexane; 2,4- and2,6-hexahydrotoluenediisocyanate, as well as the corresponding isomericmixtures; 4,4'-, 2,2- and 2,4'-dicyclohexylmethanediisocyanate, as wellas the corresponding isomeric mixtures.

Also advantageously used for the polyisocyanate component are theso-called modified multifunctional isocyanates, i.e., products which areobtained through chemical reactions of the above diisocyanates and/orpolyisocyanates. Exemplary are polyisocyanates containing esters, ureas,biurets, allophanates and preferably carbodiimides and/or uretonimines;isocyanurate and/or urethane group containing diisocyanates orpotyisocyanates. Liquid polyisocyanates containing carbodiimide groups,uretonimine groups and/or isocyanurate rings, having isocyanate groups(NCO) contents of from 10 to 40 weight percent, more preferably from 10to 35 weight percent, can also be used. These include, for example,polyisocyanates based on 4,4'-, 2,4'- and/or 2,2'-diphenylmethanediisocyanate and the corresponding isomeric mixtures, 2,4- and/or2,6-toluenediisocyanate and the corresponding isomeric mixtures, 4,4'-,2,4'- and 2,2'-diphenylmethanediisocyanate and the correspondingisomeric mixtures; mixtures of diphenylmethane diisocyanates and PMDIand mixtures of toluenediisocyanates and PMDI and/or diphenylmethanediisocyanates.

Suitable also are prepolymers having NCO contents of from 5 to 40 weightpercent, more preferably from 15 to 30 weight percent. These prepolymersare prepared by reaction of polyisocyanates with materials includinglower molecular weight diols, triols, but also they can be prepared withmultivalent active hydrogen compounds such as di- and tri-amines and di-and tri-thiols. Individual examples are aromatic polyisocyanatescontaining urethane groups, preferably having NCO contents of from about5 to about 40 weight percent, more preferably about 20 to 35 weightpercent, obtained by reaction of diisocyanates and/or polyisocyanateswith, for example, lower molecular weight diols, triols, oxyalkyleneglycols, dioxyalkylene glycols or polyoxyalkylene glycols havingmolecular weights up to about 800. These polyols can be employedindividually or in mixtures as di-and/or polyoxyalkylene glycols. Forexample, diethylene glycols, dipropylene glycols, polyoxyethyleneglycols, polyoxypropylene glycols and polyoxypropylenepolyoxyethyleneglycols can be used.

Particularly useful in the present invention are: (i) polyisocyanateshaving an NCO content of from 8 to 40 weight percent containingcarbodiimide groups and/or urethane groups, from 4,4'-diphenylmethanediisocyanate or a mixture of 4,4'- and 2,4'-diphenylmethanediisocyanates; (ii) prepolymers containing NCO groups, having an NCOcontent of from 20 to 35 weight percent, based on the weight of theprepolymer, prepared by the reaction of polyoxyalkylene polyols, havinga functionality of preferably from 2 to 4 and a molecular weight of fromabout 800 to about 15,000 with 4,4'-diphenylmethane diisocyanate or witha mixture of 4,4'- and 2,4-diphenylmethane diisocyanates and mixtures of(i) and (ii); and (iii) 2,4- and 2,6-toluene-diisocyanate and thecorresponding isomeric mixtures. PMDI in any of its forms can also beused and is preferred. In this case it preferably has an equivalentweight between about 125 and about 300, more preferably from about 130to about 175, and an average functionality of greater than about 2. Morepreferred is an average functionality of from about 2.0 to about 3.5.The viscosity of the polyisocyanate component is preferably from about25 to about 5,000 centipoise (cps) (0.025 to about 5 Pa.s), but valuesfrom about 100 to about 1,000 cps at 25° C. (0.1 to 1 Pa.s) arepreferred for ease of processing. Similar viscosities are preferredwhere alternative polyisocyanate components are selected.

In preparing the polymers of the present invention, an "A" component(which includes the polyisocyanate) is mixed with a "B" component whichis an active hydrogen containing compound. The active hydrogencontaining compounds of the "B" component can be either the same asthose used to prepare the prepolymer of the "A" component, if the Acomponent is a prepolymer, or they can be different. Active hydrogencontaining compounds most commonly used are those compounds having atleast two hydroxyl groups. Those compounds are referred to herein aspolyols. Representatives of suitable polyols are generally known and aredescribed in such publications as High Polymers, Vol. XVI,"Polyurethanes, Chemistry and Technology" by Saunders and Frisch,Interscience Publishers, New York, Vol. I, pp. 32-42, 44-54 (1962) andVol. II, pp. 5-6,198-199 (1964); Organic Polymer Chemistry by K. J.Saunders, Chapman and Hall, London, pp. 323-325 (1973); and Developmentsin Polyurethanes, Vol. I, J. M. Burst, ed., Applied Science Publishers,pp. 1-76 (1978). However, any active hydrogen containing compound can beused with the method of this invention. Examples of such materialsinclude those selected from the following classes of compositions, aloneor in admixture: (a) alkylene oxide adducts of polyhydroxyalkanes; (b)alkylene oxide adducts of non-reducing sugars and sugar derivatives; (c)alkylene oxide adducts of phosphorus and polyphosphorus acids; and (d)alkylene oxide adducts of polyphenols. Polyols of these types arereferred to herein as "base polyols". Examples of alkylene oxide adductsof polyhydroxyalkanes useful herein are adducts of ethylene glycol,propylene glycol, 1,3-dihydroxypropane, 1,4-dihydroxybutane, and1,6-dihydroxyhexane, glycerol, 1,2,4-trihydroxybutane,1,2,6-trihydroxyhexane, 1,1,1-trimethylolethane,1,1,1-trimethylolpropane, pentaerythritol, polycaprolactone, xylitol,arabitol, sorbitol, mannitol, and the like. Preferred herein as alkyleneoxide adducts of polyhydroxyalkanes are the ethylene oxide adducts oftrihydroxyalkanes. Other useful adducts include ethylene diamine,glycerine, ammonia, 1,2,3,4-tetrahydroxy butane, fructose, and sucrose.

Also preferred are poly(oxypropylene) glycols, triols, tetrols andhexols and any of these that are capped with ethylene oxide. Thesepolyols also include poly(oxypropyleneoxyethylene)polyols. Theoxyethylene content should preferably comprise less than about 80 weightpercent of the total and more preferably less than about 40 weightpercent. The ethylene oxide, when used, can be incorporated in any wayalong the polymer chain, for example, as internal blocks, terminalblocks, or randomly distributed blocks, or any combination thereof.

Polyamines, aromatic polyester polyols, aliphatic polyester polyols,amine-terminated polyols, polymercaptans and other isocyanate-reactivecompounds are also suitable in the present invention. Polyisocyanatepolyaddition active hydrogen containing compounds (PIPA) areparticularly preferred for use with the present invention. PIPAcompounds are typically the reaction products of TDI andtriethanolamine. A method for preparing PIPA compounds can be found in,for example, U.S. Pat. No. 4,374,209, issued to Rowlands.

Another preferred class of polyols are "copolymer polyols", which arebase polyols containing stably dispersed polymers such asacrylonitrile-styrene copolymers. Production of these copolymer polyolscan be from reaction mixtures comprising a variety of other materials,including, for example, catalysts such as azobisisobutyronitrile;copolymer polyol stabilizers; and chain transfer agents such asisopropanol.

The polymer foams of the present invention are prepared using blowingagents. The polyisocyanates of the present invention are advantageouslyreacted with active hydrogen compounds in the presence of a blowingagent. Any blowing agent or mixture thereof is suitable for use in thepractice of the present invention. Suitable blowing agents includeinorganic blowing agents such as water, organic blowing agents which arevolatile at reaction temperatures and dissolved inert gases. Suitableorganic blowing agents include acetone; ethyl acetate; methanol;ethanol; halogen-substituted alkanes such as methylene chloride,chloroform, ethylidene chloride, trichlorofluoromethane,1,1-dichloro-1-fluoroethane, 1,1,1,2-tetrafluoroethane,chloro-difluoromethane, dichlorodi-fluoromethane and the like; butane;pentane; hexane; heptane; diethyl ether; and the like. Gases inert tothe starting components such as nitrogen, air, carbon dioxide and thelike are also useful blowing agents. Compounds, such as azides, whichdecompose at suitable temperatures to produce gases such as nitrogen arealso useful. Preferred blowing agents are compounds which boil betweenabout -50° and 100° C., more preferably between about -40° and 50° C.

The amount of blowing agent employed is not critical to the invention,but is preferably sufficient to foam the reaction mixture. The amountwill vary with factors such as the density desired in a foamed product.

Water is a useful blowing agent for use in the practice of theinvention. In addition to generating carbon dioxide gas for foaming,water reacts quickly with polyisocyanate components, thus contributingto early polymer strength needed for gas retention. Generally, whenwater is used, it is present in proportions of from about 0.4 to about 8weight percent of water based on total weight of active hydrogencontaining compositions or B component. Other blowing agents, can beused in combination with water.

The present invention includes polymers such as polyurethanes,polyisocyanurates and polyureas. Polyurea formulations often can be selfcatalyzing. Polyurethane and polyisocyanurate foam formulations usuallyinclude a catalyst. Polyurethane catalysts are suitably used with thepresent invention. The catalyst is preferably incorporated in theformulation in an amount suitable to increase the rate of reactionbetween the isocyanate groups of the composition of the presentinvention and a hydroxyl-reacting species. Although a wide variety ofmaterials is known to be useful for this purpose, the most widely usedand preferred catalysts are the tertiary amine catalysts and theorganotin catalysts.

Examples of the tertiary amine catalysts include, for example,triethylenediamine, pentamethyldiethylenetriamine, N-methyl morpholine,N-ethyl morpholine, diethylethanolamine, N,N-dimethylcyclohexylamine,dimethyl-ethanolamine, N-coco morpholine, 1-methyl-4-dimethylaminoethylpiperazine, 3-methoxy-N-dimethylpropylamine, N,N-diethyl-3-diethylaminopropylamine, dimethylbenzyl amine and the like. Tertiary aminecatalysts are advantageously employed in an amount from about 0.01 toabout 5 percent by weight of the polyol formulation.

Examples of organotin catalysts include dimethyltin dilaurate,dibutyltin dilaurate, dioctyltin dilaurate, stannous octoate and thelike. Other examples of effective catalysts include those taught in, forexample, U.S. Pat. No. 2,846,408. Preferably the organotin catalyst isemployed in an amount from about 0.001 to about 0.5 percent by weight ofthe polyol formulation.

Suitable catalysts for use with the present invention include thosewhich catalyze the formation of isocyanurates such as those mentioned inSaunders and Frisch, Polyurethanes, Chemistry and Technology in 1 HighPolymers Vol. XVI, pp. 94-97 (1962). Such catalysts are referred toherein as trimerization catalysts. Examples of these catalysts includealiphatic and aromatic tertiary amine compounds, organometalliccompounds, alkali metal salts of carboxylic acids, phenols andsymmetrical triazine derivatives. Preferred catalysts are potassiumsalts of carboxylic acids such as potassium octoate and the potassiumsalt of 2-ethylhexanoic acid and tertiary amines such as, for instance,2,4,6-tris(dimethyl aminomethyl) phenol.

Also suitable used with the present invention are fillers and additives.Fillers are generally inorganic materials which can be used to displacemore expensive organic components and sometimes improve certain physicalproperties for example, chopped glass, glass fibers, kaolins, and thelike can be included in the formulations of the present invention.Additives are generally materials added to a polymer formulation toimpart some special property for example, conductivity inducing agents,flame retardants, pigments, and the like can all be included in theformulations of the present invention. Any filler or additive known tothose skilled in the art of preparing polymer foams to be useful can beuser with the present invention.

The surfactants of the present invention can be used to preparepolyurethane polymers. In two component (A and B) polyurethane polymerformulations, the uncapped non-silicone surfactants can be included inthe B side wherein they are generally stable. Alternatively, theuncapped non-silicone surfactants of the present invention can beincluded in the A side wherein they can be used to form a prepolymer.The capped surfactants of the present invention can be included ineither the A side or the B side. Where appropriate, an active hydrogenreactive group containing capping compound can be used to prepare asurfactant useful for forming a B side prepolymer. In three componentpolyurethane formulations, wherein the 3rd or "C" component is acatalyst, all or part of the no-silicone surfactant of the presentinvention can also included therein.

The surfactants of the present invention are included in polyurethaneformulations at a concentration suitable to perform the desiredfunctions of foam stabilization and reaction mixture compatibilization.Due to the wide variations in weight ratios of polyurethane formulationcomponents, it is customary in the art of preparing polyurethanes tospecify surfactant loadings as parts surfactant per 100 parts polyol inthe B side of the formulation. For purposes of the present invention,the concentration of non-silicone surfactants of the present inventionin polyurethane formulations shall be measured as parts surfactant per100 parts active hydrogen including compounds in the B side, notincluding the surfactants. Preferably, the non-silicone surfactants ofthe present invention are present at a reaction mixture concentration offrom about 0.25 parts to about 20 parts per 100 parts of active hydrogenincluding compounds, more preferably from about 0.5 parts to about 10parts per 100 parts of active hydrogen including compounds, and evenmore preferably from about 1 part to about 5 parts per 100 parts ofactive hydrogen including compounds.

The following examples are provided to illustrate the present invention.The examples are not intended to limit the scope of the presentinvention and they should not be so interpreted. Amounts are in weightparts or weight percentages unless otherwise indicated.

EXAMPLE 1

A non-silicone polyether surfactant is prepared by charging 656 grams of1,2-propylene glycol containing about 6 percent KOH into a closed systemreaction vessel. The reactor is sealed and heated to 130° C. 5645 gramsof 1,2-butylene oxide is fed into the reactor at rate sufficient toavoid exceeding 70 psi (482.6 kPa) and until subsequent pressure dropsare less than 0.5 psi (3.4 kPa) per hour. 3767 grams of thisintermediate material are removed from the reactor. Next, 597 grams ofethylene oxide are fed into the reactor. After the pressure drop isstabilized, the polyether surfactant is analyzed. The resultingpolyether surfactant has a molecular weight of about 902, a weightpercent oxybutylene groups (hereinafter BO) of 72.5, a weight percentoxyethylene groups (hereinafter EO) of 19.1 and a nominal functionalityof 2.

A polymer foam is prepared by admixing the formulation disclosed belowin Table 1 by first admixing thoroughly a polyol, catalyst, surfactantand blowing agent in a plastic cup. Next, PMDI is added to the cup andthe admixture is stirred at 1,500 rpm using a 4 in. (10.2 cm) impellerattached to a drill press. The polymerizing admixture is poured into a14 in.×14 in. 14 in. (35.6 cm×35.6 cm×35.6 cm) box mold and allowed torise. Physical properties and the reaction profile for the polymer foamare determined and recorded below in Table 2.

EXAMPLE 2

A polymer foam is prepared and tested substantially identically toExample 1 except that a polyether surfactant having a molecular weightof 1,836, a weight percent BO of 53.2, a weight percent EO of 42.6 and anominal functionality of 2 is used. Physical properties and the reactionprofile for the polymer foam are determined and recorded below in Table2.

EXAMPLE 3

A polymer foam is prepared and tested substantially identically toExample 1 except that a polyether surfactant initiated withtriethyleneglycol monomethyl ether and having a molecular weight of1,428, a weight percent BO of 44.6, a weight percent EO of 50.0 and anominal functionality of 2 is used. Physical properties and the reactionprofile for the polymer foam are determined and recorded below in Table2.

COMPARATIVE EXAMPLE 4

A polymer foam is prepared and tested substantially identically toExample 1 except that a conventional silicone based surfactant is used.Physical properties and the reaction profile for the polymer foam aredetermined and recorded below in Table 2.

                  TABLE 1                                                         ______________________________________                                        CONCENTRATION IN WEIGHT PARTS                                                 EXAMPLE NUMBER 1        2       3     Comp. 4*                                ______________________________________                                        Polyol.sup.1   100.0    100.0   100.0 100.0                                   Surfactant A   1.5      --      --    --                                      Surfactant B   --       1.5     --    --                                      Surfactant C   --       --      1.5   --                                      Conventional Silicone                                                                        --       --      --    1.5                                     Surfactant.sup.2                                                              Urethane Catalyst.sup.3                                                                      0.23     0.23    0.23  0.23                                    Isocyanurate Catalyst.sup.4                                                                  1.8      1.8     1.8   1.8                                     Blowing Agent.sup.5                                                                          40.6     40.6    40.6  40.6                                    Polyisocyanate.sup.6                                                                         158.9    158.9   158.9 158.9                                   ______________________________________                                         NOT AN EXAMPLE OF THE PRESENT INVENTION                                       .sup.1 STEPANPOL PS2502** which is an aromatic polyester polyol having a      hydroxyl number of 250 (**STEPANPOL PS2502 is a trade designation of the      Stepan Company).                                                              .sup.2 Organosiloxanepolyether copolymer surfactant.                          .sup.3 POLYCAT 8 is a N,Ndimethylcyclohexylamine catalyst and is a trade      designation of Air Products and Chemicals, Inc.                               .sup.4 HEXCEM 977 is a potassium salt of 2ethylhexanoic acid in diethylen     glycol and is a trade designation of OM Group, Inc.                           .sup.5 CFC11 is a trichlorofluoromethane blowing agent.                       .sup.6 A PMDI having a viscosity of 700 cps (0.7 NS/m.sup.3) and a            isocyanate equivalent weight of about 139.                               

                  TABLE 2                                                         ______________________________________                                        EXAMPLE                                                                       NUMBER       1        2        3      Comp. 4*                                ______________________________________                                        REACTION                                                                      PROFILE.sup.1                                                                 Cream Time   20       22       20     23                                      Gel Time     44       45       45     55                                      Rise Time    71       76       60     73                                      Core Density.sup.2                                                                         1.49/23.9                                                                              1.44/23.0                                                                              1.56/25.0                                                                            1.52/24.3                               pcf/(kg/cm.sup.3)                                                             K-factor.sup.3                                                                             0.129    0.124    0.122  0.128                                   COMPRESSIVE                                                                   STRENGTH.sup.4 psi/kPa                                                        Parallel to Rise                                                                           27.6/    24.3/    31.0/  34.4/                                                190.3    167.5    213.7  237.2                                   Perpendicular to                                                                           14.2/    14.0/    16.8/  16.4/                                   Rise(1)      97.9     96.5     115.8  113.1                                   Perpendicular to                                                                           14.8/    14.1/    16.5/  15.0/                                   Rise(2)      102.0    97.2     113.8  103.4                                   ______________________________________                                         *NOT AN EXAMPLE OF THE PRESENT INVENTION                                      .sup.1 The reactivity profile can be determined by measuring the time fro     mixing of a polyioscyanate or an admixture of polyisocyanates with an         active compound until specific phenomena are observed in a forming            polyurethane or polyisocyanate foam. The measurements of foam forming         ability include:                                                              a) Cream time: the time in seconds from mixing until foaming begins,          determined by observing when gas first begins to expand the admixture;        b) Gel time: the time in seconds from mixing until the foaming admixture      first begins to produce "strings" adhering to a wooden spatula quickly        inserted and removed from the foaming admixture;                              c) Rise time: the time in seconds from mixing until the foam stops rising     d) Tackfree time: the time in seconds from mixing until the foam surface      losed its sticky quality.                                                     .sup.2 ASTMD-1622-88.                                                         .sup.3 ASTMC-518-85                                                           .sup.4 ASTMD-1621-73                                                     

EXAMPLE 5

A polymer foam is prepared and tested substantially identically toExample 1 except that a formulation displayed below in Table 3 is used.The polyether surfactant has a molecular weight of about 902, a weightpercent BO of 72.5, a weight percent EO of 19.1 and a nominalfunctionality of 2. Physical properties and the reaction profile for thepolymer foam are determined and recorded below in Table 4.

EXAMPLE 6

A polymer foam is prepared and tested substantially identically toExample 5 except that a polyether surfactant having a molecular weightof 1,836, a weight percent BO of 53.2, a weight percent EO of 42.6 and anominal functionality of 2 is used. Physical properties and the reactionprofile for the polymer foam are determined and recorded below in Table4.

EXAMPLE 7

A polymer foam is prepared and tested substantially identically toExample 5 except that a polyether surfactant initiated withtriethyleneglycol monomethyl ether and having a molecular weight of1,428, a weight percent BO of 44.6, a weight percent EO of 50.0 and anominal functionality of 2 is used. Physical properties and the reactionprofile for the polymer foam are determined and recorded below in Table4.

COMPARATIVE EXAMPLE 8

A polymer foam is prepared and tested substantially identically toExample 5 except that a conventional silicone based surfactant is used.Physical properties and the reaction profile for the polymer foam aredetermined and recorded below in Table 4.

                  TABLE 3                                                         ______________________________________                                        CONCENTRATION IN WEIGHT PARTS                                                 EXAMPLE NUMBER 5        6       7     Comp. 8*                                ______________________________________                                        Polyol.sup.1   100.0    100.0   100.0 100.0                                   Surfactant A   2.1      --      --    --                                      Surfactant B   --       2.1     --    --                                      Surfactant C   --       --      2.1   --                                      Conventional Silicone                                                                        --       --      --    2.1                                     Surfactant.sup.2                                                              Urethane Catalyst.sup.3                                                                      0.20     0.20    0.20  0.20                                    Urethane Catalyst.sup.4                                                                      0.10     0.10    0.10  0.10                                    Isocyanurate Catalyst.sup.5                                                                  5.0      5.0     5.0   5.0                                     Water          2.5      2.5     2.5   2.5                                     Blowing Agent.sup.6                                                                          26.9     26.9    26.9  26.9                                    Polyisocyanate.sup.7                                                                         265.1    265.1   265.1 265.1                                   ______________________________________                                         NOT AN EXAMPLE OF THE PRESENT INVENTION                                       .sup.1 STEPANPOL PS2502** which is an aromatic polyester polyol having a      hydroxyl number of 250 (**STEPANPOL PS2502 is a trade designation of the      Stepan Company).                                                              .sup.2 Organosiloxanepolyether copolymer surfactant.                          .sup.3 POLYCAT 8 is a N,Ndimethylcyclohexylamine catalyst and is a trade      designation of Air Products and Chemicals, Inc.                               .sup.4 POLYCAT 5 is a pentamethyldiethylenetriamine catalyst and is a         trade designation of Air Products and Chemical, Inc.                          .sup.5 HEXCEM 977 is a potassium salt of 2ethylhexanoic acid in diethylen     glycol and is a trade designation of OM Group, Inc.                           .sup.6 CFC11 is a trichlorofluoromethane blowing agent.                       .sup.7 A PMDI having a viscosity of 700 cps (0.7 NS/m.sup.3) and a            isocyanate equivalent weight of about 139.                               

                  TABLE 4                                                         ______________________________________                                        EXAMPLE                                                                       NUMBER       5        6        7      Comp. 8*                                ______________________________________                                        REACTION                                                                      PROFILE.sup.1                                                                 Cream Time   21       21       21     21                                      Gel Time     72       64       58     60                                      Rise Time    94       92       95     90                                      Core Density.sup.2                                                                         1.72/27.6                                                                              1.66/26.6                                                                              1.69/27.1                                                                            1.72/27.6                               pcf/(kg/m.sup.3)                                                              K-factor.sup.3                                                                             0.149    0.158    0.157  0.155                                   COMPRESSIVE                                                                   STRENGTH.sup.4 psi/kPa                                                        Parallel to Rise                                                                           25.9/    25.1/    26.1/  37.7/                                                178.6    173.1    180/0  259.9                                   Perpendicular to                                                                           16.8/    16.9/    17.1/  17.3/                                   Rise(1)      115.8    116.5    117.9  119.3                                   Perpendicular to                                                                           15.8/    15.9/    16.1/  16.2/                                   Rise(2)      108.9    109.6    111.0  111.7                                   ______________________________________                                         NOT AN EXAMPLE OF THE PRESENT INVENTION                                       .sup.1 See note 1 in Table 2.                                                 .sup.2 ASTMD-1622-88                                                          .sup.3 ASTMC-518-85                                                           .sup.4 ASTMD-1621-73                                                     

EXAMPLE 9

A polymer foam is prepared and tested substantially identically toExample 1 except that a formulation displayed below in Table 5 is used.The polyether surfactant is initiated with a EO adduct of methanol(having a formula: MeOCH₂ CH₂ OCH₂ CH₂ OCH₂ CH₂ OH) and has a molecularweight of about 1550, a weight percent BO of 33.4, a weight percent EOof 56.1 and a nominal functionality of 1. Physical properties and thereaction profile for the polymer foam are determined and recorded belowin Table 6.

COMPARATIVE EXAMPLE 10

A polymer foam is prepared and tested substantially identically toExample 9 except that a conventional silicone based surfactant only isused. Physical properties and the reaction profile for the polymer foamare determined and recorded below in Table 6.

                  TABLE 5                                                         ______________________________________                                        CONCENTRATION IN WEIGHT PARTS                                                 EXAMPLE NUMBER     9       Comp. 10*                                          ______________________________________                                        Polyol.sup.1       100.0   100.0                                              Surfactant D       1.0     --                                                 Conventional Silicone                                                                            1.0     2.0                                                Surfactant.sup.2                                                              Urethane Catalyst.sup.3                                                                          0.60    0.60                                               Isocyanurate Catalyst.sup.4                                                                      2.3     2.3                                                Water              1.0     1.0                                                Blowing Agent.sup.5                                                                              32      32                                                 Polyisocyanate.sup.6                                                                             187.5   187.5                                              ______________________________________                                         NOT AN EXAMPLE OF THE PRESENT INVENTION                                       .sup.1 STEPANPOL PS2502** which is an aromatic polyester polyol having a      hydroxyl number of 250 (**STEPANPOL PS2502 is a trade designation of the      Stepan Company).                                                              .sup.2 Organosiloxanepolyether copolymer surfactant.                          .sup.3 POLYCAT 8 is a N,Ndimethylcyclohexylamine catalyst and is a trade      designation of Air Products and Chemicals, Inc.                               .sup.4 HEXCEM 977 is a potassium salt of 2ethylhexanoic acid in diethylen     glycol and is a trade designation of OM Group, Inc.                           .sup.5 HCFC141b is a 1,1dichloro-1-fluoroethane blowing agent.                .sup.6 A PMDI having a viscosity of 700 cps (0.7 NS/m.sup.3) and a            isocyanate equivalent weight of about 139.                               

                  TABLE 6                                                         ______________________________________                                        EXAMPLE NUMBER     9          Comp. 10*                                       ______________________________________                                        REACTION PROFILE.sup.1                                                        Cream Time         16         16                                              Gel Time           31         32                                              Rise Time          60         60                                              Core Density.sup.2 1.74/27.9  1.77/28.4                                       pcf/(kg/m.sup.3)                                                              K-factor.sup.3     0.148      0.149                                           COMPRESSIVE STRENGTH.sup.4                                                    psi/kPa                                                                       Parallel to Rise    30.7/211.7                                                                               33.0/227.5                                     Perpendicular to Rise(1)                                                                          14.8/102.2                                                                              13.9/96.0                                       Perpendicular to Rise(2)                                                                          14.8/102.0                                                                              13.8/95.1                                       BURN TEST.sup.5                                                               Smoke Release      665        765                                             Heat Release       190        186                                             Percent Weight Loss                                                                              33.7       38.3                                            ______________________________________                                         *NOT AN EXAMPLE OF THE PRESENT INVENTION                                      .sup.1 See note in Table 2.                                                   .sup.2 ASTMD-1822-88                                                          .sup.3 ASTMc-518-85                                                           .sup.4 ASTMD-1621-73                                                          .sup.5 ASTME-906-83.                                                     

EXAMPLE 11

A polymer foam is prepared substantially identically to Example 1 exceptthat a formulation displayed below in Table 7 is used. The polyethersurfactant is initiated with propylene glycol and has a molecular weightof about 6,800, a weight percent BO of 60.6, a weight percent EO of 38.3and a nominal functionality of 2. The foam is visually inspected forfoam quality. If the foam has fine cell size and is not excessivelyfriable, it passes the foam quality test which is indicated by a "+" inTable 7 below.

EXAMPLE 12

A polymer foam is prepared and tested substantially identically toExample 11 except that the surfactant has a molecular weight of about4,595, a weight percent BO of 78.9, a weight percent EO of 19.6 and anominal functionality of 2. Foam results are displayed below in Table 7below.

COMPARATIVE EXAMPLE 13

A polymer foam is prepared and tested substantially identically toExample 11 except that the surfactant is a conventional siliconesurfactant. Foam results are displayed below in Table 7 below.

                  TABLE 7                                                         ______________________________________                                        CONCENTRATION IN WEIGHT PARTS                                                 EXAMPLE NUMBER 11        12        Comp. 13*                                  ______________________________________                                        Polyol.sup.1   100       100       100                                        Surfactant B   1.0       --        --                                         Surfactant F   --        1.5       --                                         Conventional Silicone                                                                        --        --        2.0                                        Surfactant.sup.2                                                              Urethane Catalyst.sup.3                                                                      2.85      2.85      2.85                                       Isocyanurate Catalyst.sup.4                                                                  2.5       2.5       2.5                                        Water          3.7       3.7       3.7                                        Blowing Agent.sup.5                                                                          21        21        21                                         Polyisocyanate.sup.6                                                                         176.0     176.0     176.0                                      Foam Quality.sup.7                                                                           +         +         +                                          Core Density.sup.8                                                                           1.32/21.2 1.32/21.2 1.32/21.2                                  pcf/(kg/m.sup.3)                                                              ______________________________________                                         *NOT AN EXAMPLE OF THE PRESENT INVENTION                                      .sup.1 A polyether polyol having a functionality of about 3.9 and a OH        equivalent weight of 145.2.                                                   .sup.2 Organosiloxanepolyether copolymer surfactant.                          .sup.3 A mixture of tertiary amines.                                          .sup.4 CURITHANE 52 is a sodium glycinate derivative and is a trade           designation of The Dow Chemical company.                                      .sup.5 HCFC141b is a 1,1dichloro-1-fluoroethane blowing agent.                .sup.6 A polyisocyanate have an isocyanate equivalent weight of about 134     a viscosity at 25° C. of about 170 and a functionality of about 2.     .sup.7 See note in Example 11 text above.                                     .sup.8 ASTMD-1622-88                                                     

COMPARATIVE EXAMPLE 14

A polymer foam is prepared substantially identically to Example 11except no surfactant is used. The foam is tested for foam quality andfails.

COMPARATIVE EXAMPLE 15

A polymer foam is prepared substantially identically to Example 11except that an ethylene oxide/propylene oxide polyether surfactant isused. The surfactant has a molecular weight of about 6,600, a weightpercent propylene oxide of 44.4, a weight percent EO of 52 and a nominalfunctionality of 2. The foam is tested for foam quality and fails.

EXAMPLE 16

A capped non-silicon polyether surfactant is prepared by a processhaving the following steps:

1) 1013.2 grams of a butylene oxide ethylene oxide, propylene glycolinitiated block polyether surfactant having a molecular weight of about4,600 is charged into a 2 liter, 5 neck round bottom flask equipped witha vacuum distillation head, thermocouple, magnetic stirring bar, heatingmantel and nitrogen inlet tube.

2) 60 grams acetic anhydride is charged to the round bottom flask.

3) Nitrogen is purged through the polyether and acetic anhydride for 30minutes at ambient temperature.

4) The flask is heated to 85° C. for 30 minutes.

5) The material in the flask is refluxed at 100° C. for 2.5 hours.

6) The flask is at heated at 135° C. under partial vacuum for 15minutes, nitrogen being introduced into the system to minimize bumping.

7) The temperature of the flask is increased to 150° C. and held underfull vacuum until distillation is no longer visible.

8) The flask is held under full vacuum at 150° C. for an additional 15minutes.

9) The product is then purged with nitrogen at 90 Torr (12 kPa) for 4hours.

10) The product is cooled to ambient conditions.

The resultant material is a clear polyether having no measurable activehydrogen activity.

EXAMPLES 17, 18, AND COMPARATIVE 19

A polymer foam is prepared as follows:

1) A polyether surfactant is prepared substantially identically toExample 1 except that the polyether surfactant has a molecular weight ofabout 4,600; a weight percent BO of 86; a weight percent EO of 12; andethylene oxide mixed with butylene oxide 80:20 is used to prepare thesurfactant.

2) The polyether surfactant of step 1 is capped substantiallyidentically to Example 16.

3) A polymer foam is prepared and tested substantially identically toExample 1 except that the capped surfactant of Step 2 above and theformulation listed in Table 8 is used and part of the surfactants andblowing agents are first admixed with polyisocyanate. Physicalproperties are recorded and listed in Table 9.

                  TABLE 8                                                         ______________________________________                                        CONCENTRATION IN WEIGHT PARTS                                                 EXAMPLE NUMBER   17      18        Comp. 19*                                  ______________________________________                                        Polyol.sup.1     85      85        85                                         Polyol.sup.2     15      15        15                                         Non-Si Surfactant                                                                              2.47    1.23      --                                         Conventional Silicone                                                                          --      --        2.47                                       Surfactant.sup.3                                                              Urethane Catalyst.sup.4                                                                        0.25    0.25      0.25                                       Isocyanurate Catalyst.sup.5                                                                    4.0     4.0       4.0                                        Water            1.1     1.1       1.1                                        Blowing Agent.sup.6                                                                            28.9    28.9      28.9                                       Polyisocyanate.sup.7                                                                           220.1   220.1     220.1                                      Non-Si Surfactant**                                                                            0.53    0.26      --                                         Conventional Silicone                                                                          --      --        0.53                                       Surfactant.sup.3 **                                                           Blowing Agent.sup.6 **                                                                         11.0    11.0      11.0                                       ______________________________________                                         NOT AN EXAMPLE OF THE PRESENT INVENTION                                       **Included in the A side                                                      .sup.1 STEPANPOL PS2352** which is an aromatic polyester diol having a        hydroxyl number of 235 (**STEPANPOL PS2352 is a trade designation of the      Stepan Company)                                                               .sup.2 Markwhat is this polyol                                                .sup.3 Organosiloxanepolyether copolymer surfactant.                          .sup.4 POLYCAT 5 is a pentamethyldiethylene triamine catalyst and is a        trade designation of Air Products and Chemicals, Inc.                         .sup.5 HEXCEM 977 is a potassium salt of 2ethylhexamoic acid in diethylen     glycol and is a trade designation of OM Group, Inc.                           .sup.6 HCFC141b is a 1,1dichloro-1-flurorethane blowing agent.                .sup.7 PMDI having a viscosity of 700 cps (0.7 NS/m.sup.3) and a              isocyanate equivalent weight of about 139. (Is this right?)              

                  TABLE 9                                                         ______________________________________                                        EXAMPLE NUMBER 17        18        Comp. 19*                                  ______________________________________                                        REACTION PROFILE.sup.1                                                        Cream Time     17        17        17                                         Gel Time       32        32        32                                         Rise Time      41        41        41                                         Core Density.sup.2                                                                           1.78/28.5 1.74/27.8 1.76/28.2                                  pcf/(kg/m.sup.3)                                                              K-factor.sup.3 0.135     0.135     0.139                                      COMPRESSIVE                                                                   STRENGTH.sup.4 psi/kPa                                                        Prarllel to Rise                                                                              34.9/240.6                                                                              35.6/245.4                                                                              38.1/262.7                                Perpendicular to Rise                                                                        13.5/93.1 12.9/88.9 13.1/90.3                                  ______________________________________                                         *NOT AN EXAMPLE OF THE PRESENT INVENTION                                      .sup.1 See note in Table 2.                                                   .sup.2 ASTMD-1822-88                                                          .sup.3 ASTMc-518-85                                                           .sup.4 ASTMD-1621-73                                                     

What is claimed is:
 1. An active hydrogen containing compositioncomprising:(A) a polyfunctional active hydrogen containing compound, (B)an optional blowing agent, (C) an optional catalyst, and (D) anon-silicone surfactant,wherein no silicone based surfactant is requiredin the composition; wherein the non-silicone based surfactant is presentat a reaction mixture concentration of 0.25 to 20 parts per 100 parts ofactive hydrogen compounds, and wherein the non-silicone surfactant is anamine or hydroxy initiated polyether having from about 10 to about 90weight percent oxyethylene units based on the combined weight ofoxyethylene and oxyalkylene units and from about 10 to about 90 weightpercent oxyalkylene units based on the combined weight of oxyethyleneand oxyalkylene units, the oxyalkylene units having at least 4 carbonsand the polyether being substantially free of oxypropylene units, andthe non-silicone surfactant is represented by the formula:

    I-(A-((E.sub.x,B.sub.y,P.sub.z)-A'H.sub.Q,) .sub.Q').sub.R

wherein I is the non-reactive portion of an initiator; A and A' areindependently O, N, or NH; E is an oxyethylene group; B is anoxyalkylene group of 4 or more carbon atoms; P is an oxypropylene group;x, y are values such that the ratio of x:y is from 1:4 to 4:1; z is avalue such that the total weight of oxypropylene units is less than 10percent of the combined weight of oxyethylene units and oxyalkyleneunits; R is from 1 to 8 depending upon the functionality of theinitiator; Q and Q' are independently 1 if A or A' is 0 or NH, and Q andQ' are independently 2 if A or A' is N; the total molecular weight ofthe compound is from 750 to 11,000; and E and B are in blocks.
 2. Theactive hydrogen containing composition of claim 1 wherein the optionalblowing agent is present.
 3. The active hydrogen containing compositionof claim 2 wherein the blowing agent is water.
 4. The active hydrogencontaining composition of claim 1 wherein the surfactant is a polyetherhaving a weight ratio of oxyethylene units to other oxyalkylene units offrom about 1:3 to about 3:1.
 5. The active hydrogen containingcomposition of claim 4 wherein the surfactant is a polyether having afunctionality of from about 1 to about
 8. 6. The active hydrogencontaining composition of claim 5 wherein the surfactant is a polyetherhaving a functionality of from about 2 to about
 4. 7. The activehydrogen containing composition of claim 6 wherein the surfactant is apolyether having a functionality of from about 2 to about
 3. 8. Theactive hydrogen containing composition of claim 1 wherein the surfactantis a polyether having oxyethylene units and oxybutylene units.
 9. Theactive hydrogen containing composition of claim 8 wherein the surfactantis prepared with an initiator including catalytic groups.
 10. The activehydrogen containing composition of claim 1 wherein the active hydrogencontaining compound is a base polyol.
 11. The active hydrogen containingcomposition of claim 1 wherein the active hydrogen containingcomposition includes a silicone surfactant.
 12. A composition preparedby a process comprising capping an amine or hydroxy initiated polyetherwith a material which is reactive with an amine or hydroxy group, thepolyether having from about 10 to about 90 weight percent oxyethyleneunits based on the combined weight of oxyethylene and oxyalkylene unitsand from about 10 to about 90 weight percent oxyalkylene units based onthe combined weight of oxyethylene and oxyalkylene units, theoxyalkylene units having at least 4 carbons, and the polyether beingsubstantially free of oxypropylene units, the composition having thegeneral formula:

    I-(A((E.sub.x,B.sub.y,P.sub.z)-A'-(C).sub.Q).sub.Q ').sub.R)

wherein I is the non-reactive portion of an initiator; A and A' areindependently O, N, or NH; E is an oxyethylene group; B is anoxybutylene group; P is an oxypropylene group; x, y are values such thatthe ratio of x:y is from 1:4 to 4:1; z is a value such that the totalweight of oxypropylene units is less than 10 percent of the combinedweight of oxyethylene units and oxybutylene units; R is from 1 to 8depending upon the functionality of the initiator; Q and Q' areindependently 1 if A or A' is O or NH and Q and Q' are 2 if A or A' isN; the total molecular weight of the compound is from 750 to 11,000; Cis the remainder of a capping compound; and E and B are in blocks.
 13. Acomposition of matter having the general formula:

    I-(A-((E.sub.e,B.sub.y P.sub.z)-A'-(C).sub.Q).sub.Q').sub.R

wherein I is the non-reactive portion of an initiator; A and A' areindependently O, N, or NH; E is an oxyethylene group; B is anoxybutylene group; P is an oxypropylene group; x, y are values such thatthe ratio of x:y is from 1:4 to 4;1; z is a value such that the totalweight of oxypropylene units is less than 10 percent of the combinedweight of oxyethylene units and oxybutylene units; R is from 1 to 8depending upon the functionality of the initiator; Q and Q' areindependently 1 if A or A' is O or NH and Q and Q' are 2 if A or A' isN; the total molecular weight of the compound is from 750 to 11,000; Cis the remainder of a capping compound; and E and B are in blocks.